Powered Industrial Truck

29 CFR 1910.178
Final Rule

1.5 million workers operating nearly 1 million

powered industrial trucks.

Roughly 100 workers killed per year

related to powered industrial truck
operations :
95,000 Injured (lost work days) per year
Lack of training is one cause of powered
industrial truck accidents. OSHA notes that
many of the accidents listed could have been
caused by improper training.

Powered Industrial Truck

Source: OSHA Analysis of Serious
Accident Reports 1984-1991

Operator inattention --------------------- 59

Overturn ------------------------------------ 53
Unstable load------------------------------- 45
Operator struck by load------------------ 37
Elevated employees ----------------------- 26
No training --------------------------------- 19
Overload, improper use ----------------- 15
Accident during maintenance-----------14

Powered Industrial Truck

Source: OSHA Analysis of Serious
Accident Reports 1984-1991 Cont..

Improper equipment-----------------------10
Obstructed view --------------------------- 10
Falling from platform or curb ----------- 9
Carrying excess passenger---------------- 8
Other employee struck by load---------- 8
Falling from trailer ------------------------ 6
Vehicle left in gear-------------------------- 6
Speeding -------------------------------------- 5

Effective date: March 1, 1999

Compliance date: December 1, 1999
OSHA estimates that - after its
regulations are fully effective late this
year - the U.S. will begin saving 11 of
those lives and avoiding 10% of the
current toll of injuries in the U.S.
Or, one life a month.

Powered Industrial Fork Truck

1.

Carbon monoxide levels were in excess of American

Conference of Governmental Industrial Hygienists
(ACGIH) 25 ppm. OSHA 50ppm.
A daily forklift inspection was not being performed.
There was no audible or visual warning device on the
industrial vehicle, or it was defective.
A powered industrial trucks horn was not used as
required.
The nameplate was not legible (or missing) on a
powered industrial truck.
Forklift truck attachments did not have the capacity
clearly and conspicuously marked on them.

Powered Industrial Fork Truck Cont. #7 =11

Fork extensions were being used or were available for
use, to extend the length of the existing forks.
Written approval from the fork truck manufacture had
not been obtained, nor was the nameplate changed to
reflect the weight capacity changes when using these
extensions.
An additional counter weight was added
A powered industrial truck was being used in a
unapproved area. Not rated for the location.
Was not equipped with a backrest extension
A broken/missing LPG strap.

Powered Industrial Fork Truck Cont. # 12=17

Wheel chocks were not used

A warehouse order picker fork truck was not provided with fall
protection equipment for the operator.
A forklift truck was left unattended (25 Ft) with its forks up
and/or its motor running
There was an open-sided floor, elevated shipping dock platform,
runway, or ramp used for fork truck travel that was
unguarded.
The lifting cage did no have a seventy-two inch mast guard or
the platform was not properly designed i.e. guardrailing
damaged, means of securing platform to the fork truck was
missing or damaged.
An employee was raised in a lifting cage with no means of
controlling the vertical travel. The driver was not in attendance.

Powered Industrial Fork Truck Cont. #18= 24

Battery Operated
A specific area was not set aside for charging batteries
Battery charger(s) were not protection to prevent damage by a
fork trucks.
NO Smoking or Open Flame signs were not posted
A fire extinguisher was not available in the battery charging area
An emergency shower was not provided or was defective.
Access to an emergency eyewash unit was blocked
Eyewash units were not activated to flush the line and to verify
proper operation (15 minuets)
A portable eye wash station was not maintained or inspected.

Development of a Training
Program
1910.178 (L)(2)(ii)-Training must consist of a
combination of formal classroom instruction,
operator practical exercises, and evaluation of the
operators performance in the workplace
1910.178 (L)(2)(iii)-All operator training and
evaluation shall be conducted by persons who
have the knowledge, training, and experience to
train powered industrial truck operators and
evaluate their competence

Training Program Content:

1910.178 (L)(3) Powered industrial truck operators shall receive
initial training in the following topics, except in
topics which the employer can demonstrate are
not applicable to safe operation of the truck in the
employers workplace

Truck Related Topics Content:

1910.178 (L)(3)(i) (A) All operating instructions - warnings and
precautions for the types of trucks the operator will be
authorized to operate
(B) Similarities to, and differences from the automobile:
Forklift

Automobile

Narrow wheel track

Short wheelbase
High structure
3-point suspension
Center of Gravity is higher
and moves in a significant
range w/loads
3 or 4 wheels, Steers from the
rear

Wide wheel track

Long wheelbase
Low structure
4- point suspension
Center of Gravity is low and
moves in a narrow range
4 wheels , Steers from the front

Truck Related Topics Content:

1910.178 (L)(3)(i)- Continued
(C) Controls & Instruments - Location, What they do,
How they operate
(D) Engine or Motor - operation and maintenance
(E) Steering & Maneuvering
(F) Visibility - including restrictions due to loading
(G) Fork and attachments - adaptation operations and
limitations
(H) Vehicle capacity
(I) Vehicle stability

Truck Related
Content Continued:
1910.178 (L)(3)(I)
(J) Vehicle Inspection and maintenance / that
the operator will be required to perform
(K) Refueling and/or charging, recharging
batteries
(L) Operating limitations - and
(M) Any other operating instructions, warnings
or precautions listed in the operator's manual
for the types of vehicles that the employee is
being trained to operate

Workplace Related Topics Content

Continued: 1910.178 (L)(3)(ii)
(A) Surface conditions where the vehicle will be
operated
(B) Composition of loads to be carried & load
stability
(C) Load manipulation, stacking , unstacking
(D) Pedestrian traffic in areas where vehicle
will be operated
(E) Narrow aisles and other restricted places
(F) Hazardous classified locations

Workplace Related Content

Continued: 1910.178 (L)(3)(ii)
(G) Ramps and other sloped surfaces that could
effect the vehicles stability
(H) Closed environments and other areas
where insufficient ventilation or poor
maintenance could cause a buildup of carbon
monoxide or diesel exhaust
(I) Other unique or potentially hazardous
environmental conditions in the workplace
that could affect safe operation

Other Hazards

Falling Loads
Falling from Platforms, Curbs, Trailers, etc..
Obstructed Views
Inattention
Riders
Vehicle Not Maintained
Carbon Monoxide
Rough - Uneven - Unleveled floors
Unusual Loads
Classified Areas
Narrow Aisles
Pedestrians

Training program
implementation
1910.178 (L)(2)(i) - Trainees may operate a
powered industrial truck only:
1910.178 (L)(2)(i)(A) - Under the direct
supervision of a person who has the knowledge,
training, and experience to train operators and
evaluate their competence; and,
1910.178 (L)(2)(i)(B) - Where such operator
does not endanger the trainee or other
employees

Refresher Training
1910.178 (L)(4)(ii)
Refresher training in relevant topics shall be
provided to the operator when:
A: The operator has been observed to operate
the vehicle in an unsafe manner
B: When the operator has been involved in an
accident or a near miss incident
C: When the operator has received an
evaluation that reveals that the operator is not
operating the truck

Refresher Training Continued:

1910.178 (L)(4)(ii)
D: The operator is assigned to drive a different
type of truck; or
E: A condition in the workplace changes in a
manner that could affect safe operation of the
truck

Refresher Training and Evaluation

1910.178 (L) (4)(i)
Refresher training , including an evaluation of the
effectiveness of that training, shall be
conducted as required by paragraph (L)(4)(ii)
to ensure the operator has the skills needed to
operate the powered industrial truck safely

Evaluation
1910.178 (L)(4)(iii)
An evaluation of each powered industrial
truck operators performance shall be
conducted at least every three years

Operator Qualification
1910.178 (L)(1)(i) - The employer shall ensure: each
potential operator is competent to operate a powered
industrial truck safely, as demonstrated by the
successful completion of the training and evaluation
specified in this paragraph (L)
1910.178 (L)(1)(ii) - Prior to permitting an employee to
operate a powered industrial truck (except for training
purposes) the employee has successfully completed the
training required by this paragraph (L), except as
permitted by paragraph (L)(5)

Certification
1910.178 (L)(6)
The employer shall certify that each operator
has :
Has been trained and evaluated as required in
paragraph (L)
The certification shall include:
Name of Trainee Operator
Date of Training
Date of the Evaluation
Identify the person(s) performing the training
and evaluation

Fork Truck Barrier

Things You Should Not Drop